Regulador de Voltaje TM-759 - 430391C

TM-759
092280
Revised 031783
Revised 082583 t GROUND POWER 1
Revised 033190
Revised 012094
i iI
OPERATION AND MAINTENANCE MANUAL

with
ILLUSTRATED PARTS LIST
for
MAGNETIC AMPLIFIER
VOLTAGE REGULATORS
Part Numbers
43039lB, 43039lC, and 281407
CAUTION: Improper flashing will damage these regulators! Never flash the exciter field
winding of equipment using one of these regulators with a grounded terminal battery.
Disregard any instructions which tell you to ground the exciter winding or the battery
providing the flashing voltage. The main generator output will be short-circuited by the
ground.
HOBART BROTHERS COMPANY

GROUND POWER DIVISION
TROY, OHIO 45373
U.S.A.
TM-759 I Operation and Maintenance Manual
Magnetic Amplifier Voltage Regulators
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ii, ’
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Unusual Service Conditions January 20/94 Revised

Page 2
Safety Instructions and Warnings for Electrical Power Equipment
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
ELECTRIC A C FLASH can injure eyes, burn skin, cause equipment damage,
and ignite corn% ustible material. DO NOT use power cables to break load and
prevent tools from causing short circuits.
!
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage
this and attached equipment.
If’TlpOl?Gtlt: Protect all operating personnel. Read, understand, and follow all instructions
in the Operating/Instruction Manual before installing, operating, or servicing
the equipment. Keep the manual available for future use by all operators.
a. General
Equipment that supplies electrical power can cause serious injury or death, or damage to other
equipment or property. The operator must strictly observe all safety rules and take precautionary
actions. Safe practices have been developed from past experience in the use of power source
equipment, While certain practices below apply only to electrically-powered equipment, other practices
apply to engine-driven equipment, and some practices to both.
1. Shock Prevention
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn
what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber
mat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,
and never work alone
a. Insta!lation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed
and maintained in accordance with the National Electrical Code, ANSVNFPA 70, or other applicable
codes. A power disconnect switch or circuit breaker must be located at the equipment. Check the
nameplate for voltage, frequency, and phase requirements. If only 3-phase power is available,
connect any single-phase rated equipment to only two wires of the 3-phase line. DO NOT
CONNECT the equipment grounding conductor (lead) to the third live wire of the 3-phase line, as
this makes the equipment frame electrically HOT, which can cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSVNFPA 70 for details. Do not remove plug ground prongs. Use
correctly mating receptacles.
b. Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair
cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while
equipment is energized.
Safety Instructions 910082 Sept l/90 Page i

c. Service and Maintenance
This equipment must be maintained in good electrical and mechanical condition to avoid hazards
stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and
discontinue use of the equipment until its safety has been assured. Repairs should be made by
qualified personnel only.
(7) Before inspecting or servicing electrically-powered equipment, take the following precautions:
(2) Shut OFF all power at the discbnmecting switch or line breaker before inspecting or servicing the
equipment.
(3) Lock switch OPEN (orremove line ruses) so that power cannot be turned on accidentally.
(4) Disconnect power to equipment if it is out of service.
(5) If troubleshooting must be done with the unit energized, have another person present who is
trained in turning off the equipment and providing or calling for first aid.
2. Fire And Explosion Prevention

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
piping, misuse of batteries and fuel, or unsafe operating or fueling conditions.
a. Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by
causing nearby combustibles to ignite. For electrically-powered equipment, provide primary input
protection to remove short circuited or heavily overloaded equipment from the line.
b. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or
use open flame near the battery.
c. Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank
is not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DO
NOT completely till tank, because heat from the equipment may cause fuel expansion overflow.
Remove all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open
equipment doors and blow fumes away with compressed air.
3. Toxic Fume Prevention

Carbon monoxide - Engine exhaust fumes can kill and cause health problems, Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
4. Bodily Injury Prevention

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment
for inspection and routine maintenance. When equipment is in operation, use extreme care in doing
necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.
5. Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate
treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a
hospital immediately if any abnormal signs are observed.
Page ii Safety Instructions 910082 Sept II90

Call physician immediately. Seek additional assistance. Use First Aid
techniques recommended- by American Red Cross until medical help
arrives.
IF BREATHI G IS DIFFICULT, give oxygen, if available, and have victim lie

down. FOR 2 l!ECTRlCAL SHOCK, turn off power. Remove victim; if not
breathing, begin artificial respiration, preferably mouth-to-mouth. If no
detectable pulse, begin external heart massage. CALL EMERGENCY
RESCUE SQUAD IMMEDIATELY.
6. Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.
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Page iv Safety Instructions 910082 Sept l/90

TM-759 / Operation and Maintenance Manual
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Table of Contents
SUBJECT CHAPTER/SECTION PAGE
SAFETY WARNING
TABLE OF CONTENTS
INTRODUCTION
1. Scope
2. Purpose
3. Customer Service
CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION
1. Unit Assembly l-l 1
2. Components l-l 1
3. Detailed Circuit Descriptions l-l 3
SECTION 2. INSTALLATION AND PREPARATION FOR USE ,

1. Installation l-2 1
A. General . . . . . . . . . . . . . ..**......................... 1-2.. . . . . . . . . . . 1
B. Connections . . . . . . . . . ..*...........*.............. l-2............ 1
2. Preparation for Use l-2 1
SECTION 3. OPERATION
1. Operating Procedures l-3 1
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Table of Contents (Continued)
SUBJECT CHAPTEFUSECTION PAGE
CHAPTER 2. MAINTENANCE
SECTION 1. SEQUENCE AND THEORY

OF OPERATION
SECTION 2. INSPECTION/CHECK
1. Inspection of Voltage Regulator 2-2 1
2. Check of Voltage Regulator 2-2 1
SECTION 3. ADJUSTMENT AND TEST

1. Adjustment Procedures 2-3 1
A. General .......................................... 2-3 ............ 1
B. Adjust Generator Output Voltage .................... 23 ............ 1
C. Adjust Line Drop Compensation For Cable Length ..... 23 ............ 1
D. Adjust Line Drop Compensation For Cable Size. ....... 23. ........... 1
E. Adjust Damping Gain .............................. 2-3. ........... 2
F. Adjust Damping Rate .............................. 2-3. ............ 2
2. Test the Voltage Regulator 2-3 3
SECTION 4. CLEANING AND REPAIR

1. Removal of Voltage Regulator 2-4 1
2. Removal of Regulator Main Components
and Subassemblies 2-4 1
3:Cleaning 2-4 1
4. Repair 2-4 1
5. Installation of Regulator Main Components
and Subassemblies 2-4 2
Table of Contents January 20194

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Magnetic Amplifier Voltage Regulators GROUND POWER
Table Of Contents (Continued)
i iI
SUBJECT ‘0 CHAPTEFUSECTION PAGE
CHAPTER 3. TROUBLESHOOTING
SECTION 1. TROUBLESHOOTING PROCEDURES

1. General 3-1 1
2. Troubleshooting Chart 3-1 1
A. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. . . . . . . .I. . . . 1
B. Use of the Troubleshooting Chart.. . . . . . . . . . . . . . . . . . . . 3-1. . . . . . . . . . . . 1
CHAPTER 4. ILLUSTRATED PARTS LIST
SECTION 1. INTRODUCTION
1. Scope 4-1 1
2. Purpose 4-1 1
3. Arrangement 4-1 1
4. Explanation of Parts List Form 4-l 1
. A. Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. . . . . . . . . . , . 1
B. Parts List Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. . . . . . .,. . . . . 1
SECTION 2.Manufacturer’s Codes

1. Explanation of Manufacturer’s Code List 4-2 1
SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement 4-3 1
2. Symbols and abbreviations 4-3 1
SECTION 4. NUMERICAL INDEX

1. Explanation of Numerical Index 4-4 1
CHAPTER 5. MANUFACTURERS’ LITERATURE
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Table of Contents January 20194

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Introduction
1. Scope
This manual contains information and instructions for magnetic amplifier (static) voltage re$ulators, Part
Numbers 430391 B, 430391 C, and 281407, manufactured by Hobart Brothers Company, Power
Systems Group, Troy, Ohio 45373, U.S.A.
An illustrated parts list is contained in Chapter 4.
2. Purpose
The purpose of this manual is to provide operators and maintenance personnel with instructions and
information which will guide and assist them in the efficient operation and maintenance of this
equipment.
3. Customer Service
If you have any questions concerning your Hobart Power Systems Group equipment, you are invited to
contact our Service Department by mail, telephone, or FAX.
Write: Hobart Brothers Company
Power Systems Group
Service Department
Troy, Ohio 45373, U.S.A.
Call: Area Code (513) 332-5060
FAX: (513) 339-5335
January 20/94 Revised Introduction

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Introduction January 20/94 Revised

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Chapter 1 Description/Operation
n
Section 1. Description
1. Unit Assembly
The voltage regulators covered by this manual are designed to provide 1% voltage regulation with 0.25
second recovery time for all loads up to 100% of rated load on a three-phase, four-wire 115/200 volt,
400-Hz brushless alternator. These regulators provide field excitation power for a rotary exciter and
regulates alternator voltage by varying the exciter field power as required to meet varying alternator
load conditions to hold the alternator voltage constant. The maximum continuous rating of these
regulators is 4.0 amperes at 125-V DC. Figure 1 shows the 430391 C voltage regulator.
Voltage regulator 430391 C is identical to voltage regulator 430391 B except that one wire is moved to
put the diode bridge fuse in parallel with the Phase “B” sensing circuit, instead of in series with it.
The voltage regulator consists of seven basic interconnected circuits. They are:
a. Voltage detection circuit
b. Voltage comparison circuit
c. Transistorized pre-amplifier
d. Power stage full-wave single-phase magnetic amplifier
e. Damping circuit
f. Line drop compensation circuit
g. Voltage build-up circuit
Any deviation of the alternator voltage from its set, regulated level is sensed by the voltage detection
and comparison circuits. A signal is fed from the comparison circuit into the transistorized pre-
amplifier, amplified, and used to drive the magnetic amplifier. The magnetic amplifier output changes
in response to this signal, changing the field power of the rotary exciter long enough to return the
alternator voltage to its regulated value. The voltage at which the alternator is regulated may be
adjusted with the voltage adjustment rheostat.
2. Components
Refer to Figure I. Components of these basic circuits are mounted in two major subassemblies which
are the line drop compensation chassis assembly (6) and the sensing and pre-amplifier chassis
assembly (15). Receptacle connectors (7, 9, and 11) provide quick connect-disconnect facilities for
interconnecting wire leads. The two subassemblies are mounted on a chassis (18) along with other
main components of the regulator, which include a resistor (I), voltage adjusting rheostat (2) fuse (12)
and fuseholder (13) nineteen-pin receptacle connector (14), and reactor (17). (Field ballast resistors
and line drop current transformer loading resistors are located at a point remote from the voltage
regulator and are not supplied with the regulator).
January 20/94 Revised Section l-1

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, 4 17 16
I _---r
‘I .__-
e.-m* I
_____._ I
_____...___..__...________
P
1. Resistor 11. Receptacle connector

2. Regulator 12. Fuse
3. Cable length compensation rheostat 13. Fuseholder
4. Cable size compensation rheostat 14. Receptacle connector
5. On-off switch 15. Sensing and pre-amplifier chassis assembly
6. Line drop compensation chassis assembly 16. High-phase sensing board assembly
7. Receptacle connector 17. Reactor
8. Damping circuit gain potentiometer 18. Chassis
9. Receptacle connector 19. Terminal board
10. Damping circuit rate potentiometer 20. Instruction label
Magnetic Amplifier Voltage Regulator

Figure 1
Section 1-l January 20194 Revised

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3. Detailed Circuit Descriptions

a. Voltage Detection Circuit
Refer to schematic and connection diagrams at the end of this manual. This circuit consists of three
single-phase transformers (TSOl, T502, T503), three diodes (CR501, CR502, CR503) connected as
a three-phase, half-wave rectifier, six diodes (CR504 through CR509) connected as three
single-phase, full wave center-tap rectifiers, and four blocking diodes (CR510 through CR51 3). The
transformer primaries are co&&ted as a three-phase, four wire Y to the alternator output voltage.
The transformer secondaries are center-tapped with the center taps joined together to form a
common negative for the three single-phase rectifiers and the three-phase, half-wave rectifier. The
filtered output of each of the single-phase rectifiers is proportioned to a given phase voltage. The
output of the three-phase, half-wave rectifier is proportional to the average of the three generator
phase voltages. The positive outputs of the three single-phase rectifiers are connected to a
common point through blocking diodes (CR51 1 and CR513). Part of the three-phase, half-wave
rectifier voltage, as determined by the ratio of the resistors (R501 and R502) is connected through
blocking diode CR510 to this same point. The blocking diodes prevent current flow from one of the
four rectifiers into the filter circuit of any other rectifier.
The functions of the voltage detection circuit are to provide a filtered DC voltage proportional to the
alternator voltage and to sense the highest single alternator phase voltage if the phase voltages are
not balanced. The three-phase, half-wave rectifier senses the average phase voltage, and the three
single&phase, full-wave rectifiers each sense a single phase. Resistors (R501 and R502) are scaled
such that the portion of the three-phase, half-wave fed through the blocking diode (CR51 0) is
slightly higher than the three single-phase outputs when the alternator phase voltages are balanced.
If the three phase voltages are not equal, the rectifier voltage corresponding to the highest phase
voltage is higher than the average voltage signal. The output of the voltage detection circuit is thus
a filtered DC voltage proportional to the average alternator phase voltage if the voltages are
balanced and proportional to the highest phase voltage if the voltages are not balanced.
b. The Voltage Comparison Circuit
The comparison circuit is a simple voltage reference bridge consisting of three tixed resistors (R506,
R508, R509), a potentiometer (R571) and a voltage reference diode (VR501). These components
are connected to form a bridge in which the DC output of the voltage detection circuit is compared
to a fixed voltage reference. A voltage proportional to the difference between the reference and the
input voltage to the bridge appears between the slider of the potentiometer and the positive side of
the reference diode. This voltage is a function both of the generator voltage and the position of the
potentiometer slider.
The function of the voltage comparison circuit is to compare part of the DC output voltage of the
detection circuit with a fuced DC reference voltage and derive from their difference a signal suitable
for driving a DC amplifier. It is in this circuit that the voltage at which the alternator regulates is
established. Varying the position of the slider on the potentiometer changes the fraction,of the
voltage compared to the reference and varies the driving signal to the DC amplifier.
C. The Transistor Pre-Amplifier
The pre-amplifier consists of two transistors (Q501, Q502), two resistors (R507, R51 l), a zener
diode (VR502), a ‘free-wheeling” diode (CR514) and a filter capacitor (C505). These components
are connected in a two-stage DC amplifier circuit obtaining power from the three-phase, half-wave
rectifier of the voltage detection circuit and using the power to drive the control winding of the
magnetic amplifier in response to a signal from the voltage comparison bridge. Resistors (R507
and R511) limit the transistor currents to safe levels, the filter capacitor keeps the ripple low in the
input signal, and the zener diode and “free-wheeling” diode protect the output transistor from
voltage spikes from the reactor control coil. The transistorized pre-amplifier amplifies the output
signal from the voltage comparison circuit and drives the magnetic amplifier with this amplifier
output.
January 20194 Revised Section l-l

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d. The Power Stage Full-wave, Single-phase Magnetic Amplifier

This circuit consists of a single-phase, full-wave reactor (L505) and a full rectifier (CR531 through
CR534) connected as a self-saturating magnetic amplifier. The saturable reactor has two load
windings (l-2,3-4) on separate cores and two control windings (5-6,7-8) linking both cores.
The load windings are connected with the rectifiers in such a manner that only one of the load
windingsconducts for each half cycle of alternator voltage. This results in a net DC voltage on each
reactor load winding, causing th ri actor cores to saturate in the absence of a control signal. The
control winding is driven with DZJ wer in such a manner to oppose this self saturation, partially or
completely desaturating the amplifier cores in response to the pre-amplifier output.
The magnetic amplifier rectifies AC voltage from the alternator and uses the DC voltage thus ,
obtained to excite the rotary exciter in response to a control signal from the DC pre-amplifier. The
impedence of the reactor load windings, in series with the magnetic amplifier rectifier, is varied by
the control signal to wntrol exciter field power.
e. The damping circuit
The damping circuit includes a transformer (T504), a limiting resistor (R510), a variable resistor
(R551), a potentiometer (R572), and two capacitors (C506 and C507). The transformer primary is
connected to the regulator output through resistors (R510 and R551). The transformer secondary is
connected across the potentiometer. That part of the potentiometer between the slider and one end
is in series with the input of the transistor pre-amplifier and is filtered by one of the capacitors. The
other capacitor connects from the positive side of the voltage comparison circuit to the potentio-
meter.
The damping circuit detects changes in the regulator output and feeds energy pulses opposing the
changes into the transistor pre-amplifier. The damping circuit affects the transient behavior of the
regulated alternator system, preventing hunting, oscillation, and excessive overshoot of the
alternator voltage following load changes. The damping rheostat affects mostly the amplitude of the
damping signal. The rate potentiometer affects both phasing and amplitude of the signal. Capacitor
(C506) serves to shift the phase of the sensing signal, reducing the system response time.
f. The Lins Voltage Drop Compensation Circuit
The line drop compensation circuit consists of a current transformer (Tl , T2, T3) on each phase of
the load circuit, a fixed inductance (L506, L507, L508) and variable resistance (R553) in series with
each of the three phase lines leading to the voltage detection circuit, a toggle switch (S502) for
bypassing the line drop compensation, a variable resistance (R554) in series with each current
transformer input to the regulator and fixed resistance in parallel with each current transformer.
Each of the three current transformer secondaries are connected through a variable resistor to the
fixed inductance and other variable resistors.
The current transformers detect the magnitude and power factor of current flowing through the
power cables from the alternator to its load and feed a signal into the resistance and inductance
ahead of the voltage detection circuit opposing the voltage sensed by that circuit. The voltage
actually sensed by the detection circuit is therefore lower than the actual alternator voltage by an
amount proportional to the magnitude and power factor of the load current and thus proportional to
the voltage drop between the alternator and its load. The regulator output increases slightly so that
the alternator output voltage is equal to the regulated voltage plus the voltage drop in the lines. The
variable resistances may be adjusted to match exactly the impedance of the power cables carrying
the load current.
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g. The Voltage Build-Up Circuit

The voltage build-up circuit of a relay (K501) with normally closed contacts connected across the
load windings of the power reactor and a resistor (R512) in series with the relay coil. When the
machine is first started, the alternator voltage from residual magnetism is applied through the relay
contacts and the magnetic amplifier rectifier to the exciter field circuit. This causes the exciter
voltage to increase and makes the alternator voltage build up. When the alternator voltage rises
high enough to power the re ulator, the relay coil, connected to the voltage detection circuit, is
energized. This actuates th 0 relay and opens the normally closed contacts shunting the reactor
load coils, allowing the magnetic amplifier to control the exciter field power.
h. Terminal Board Circuit ,
This terminal board circuitry allows a signal from a Transformer-Rectifier (T-R), when used, to enter
the regulator and control generator output as required by the T-R load when the jumper lead
(Shown in Section 1-3, Fig. 1) is disconnected. When the jumper lead is connected, the regulator
functions normally as controlled by signals from the line drop current transformer at the generator.
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Section I-1 January 20194 Revised

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Section 2. Installation And Preparation For Use
1. Installation
a.. General i’, *
(7) This voltage regulator is designed primarily for drawer-type mounting. However, it is not attitude
sensitive and may be mounted in any position without affecting its operation. In some
installations it is mounted in what appears to be a backward position, which may make reading
the instruction plate for cable compensation adjustment somewhat difficult.
(2) The regulator does not dissipate large amounts of power, but certain components, especially the
line drop compensator rheostats and regulator power transistor, need a reasonable amount of air
for convection cooling. For this reason, the regulator should not be mounted in a small airtight
enclosure which would prevent air circulation around the line drop chassis assembly.
(3) Four mounting holes (one in each comer of the main chassis) are provided for attaching the
regulator.
(4) Position the regulator in its mounted location and install with appropriate attaching hardware
(nuts and/or screws, and washers)
b. Connections
(7) All electrical connections to the regulator are made through a nineteen pin receptacle connector
(7-7; 74, Fig. 7) which is bracket mounted on the chassis.
(2) When installing regulator, connect or disconnect the jumper wire at the terminal board (Fig. 1) as
required. See instruction label.
(3) Refer to the generator set connection diagram to determine if any jumper lead outside the
regulator should be connected - or disconnected - for a particular installation.
2. Preparation for Use

No special preparation is necessary to place the regulator in service other than the following checks
and inspections:
(7) Check all terminal lug type connections for security.
(2) Check all plug and receptacle type connectors to make certain they are firmly mated.
(3) It will be necessary to adjust a new regulator at initial start-up after installation. (See ChapterZ,
Section 3).
January 20194,Revised Section l-2

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Magnetic Amplifier Voltage Regulators l4onAKr
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‘I
HBOARD
TEFMNAL
Terminal Board on
Regulator No. 430391 B
) REMOVE BROWN JUYPER ON f Figure 1 ’
TERUINAL STRIP BELOW
FOR OPERATION OF LINE
DROP COMPENSATION ON
TRANSFORMER-RECTIFIER
VOLTAGE REGULATOR CONNECTION DIAGRAMS
FOR VOLTAGE REFER TO

REGULATOR No. PRINT No.
430391B 485319
430391 c 485319A
281407 281402
Section 1-2 January 20194 Revised

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Section 3. Operation
1. Operating Procedures I
Operating procedures, as such,/+ not applicable to the magnetic amplifier voltage regulator, because
it requires no start, stop, or operating instructions. See Chapter 2, Section 3 for initial start-up
adjustments and procedures.
Make certain that the line drop compensation switch (l-1, 5, Fig. 1) is in the ON position when
operating the generator.
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Chapter 2. Maintenance
Section I. Sequence and Theory of Operation

A description of the sequence of events, which occur when the voltage regulator is in operation, is
presented here to give maintenance personnel a better understanding of how and why the unit operates,
and thus assist them in the adjustment, troubleshooting and repair of the equipment.
a. When the machine is started, the rotary exciter is excited from the alternator residual magnetism
through the starting relay and the magnetic amplifier rectifier. As the rotary exciter voltage
increases, alternator excitation increases and the alternator voltage builds up. The voltage
detection circuit of the regulator receives this voltage, rectifies and filters it, and feeds it into the
voltage comparison circuit. When the voltage becomes high enough, the build-up relay switches
the reactor load windings into the circuit. The magnetic amplifier reactor saturates from
self-saturation, presenting a low impedence to the alternator voltage allowing the exciter field power
to increase as alternator voltage increases.
b. As the alternator voltage approaches its regulated value, the reference bridge voltage increases.
The voltage across the reference diode remains constant, clamping the emitter of the NPN input
transistor to a fuced voltage above negative. The base voltage of the transistor increases as the
bridge voltage increases. The transistor becomes forward biased and conducts, turning on the PNP
transistor in series with the reactor control coil. This allows current to flow in the magnetic amplifier
reactor control winding in a direction opposing self saturation and the reactor core becomes less
saturated. As the reactor desaturates, the impedance to the alternator voltage by the reactor load
winding increases. The rectified current flowing in the exciter field from the magnetic amplifier is
limited by the increasing reactor impedance. When the alternator voltage reaches the regulated
value, the rectified three-phase voltage of the sensing circuit is just enough to cause the magnetic
amplifier output to excite the exciter sufficiently to maintain the alternator voltage at its regulated level.
c. The voltage at which the alternator is regulated may be varied by changing the position of the slider
on the “Volts Adjust” potentiometer. This increases or decreases the potential of the base of the
pre-amplifier input transistor, changing that transistors driving signal. Increasing the potential of the
slider with respect to the detection circuit negative causes regulated voltage to decrease.
Decreasing the slider potential causes the voltage to increase.
d. Voltage Regulation
(7) Load applied
When the alternator is loaded, its terminal voltage decreases, lowering the rectified three-phase
voltage of the voltage detection circuit. The base potential of the pre-amplifier input transistor is
directly proportional to the detection circuit DC voltage, which is, in turn, directly proportional to
the alternator voltage, The potential of the emitter is the constant potential of the reference
voltage. When the alternator voltage drops, the voltage from base to emitter of the transistor
decreases. The transistor collector current, flowing from the base of the second stage transistor,
decreases, lowering the output of the second stage transistor. The lower control current in the
reactor control winding allows reactor self saturation to make the reactor core more saturated.
As the reactor saturates, its impedance decreases and the rectified current flowing in the rotary
exciter field increases. The alternator voltage increases until the voltage returns to its regulated
value.
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(2) Load removed

When a load is removed from the alternator, the alternator voltage rises. The rectified
three-phase voltage in the sensing circuit also rises, while the emitter potential clamped by
reference voltage, remains constant. The base to emitter voltage tends to increase, turning the
transistor further on. The second stage transistor turns on more, increasing the control current of
the magnetic amplifier. This causes a decrease in the reactor core saturation, decreasing the
regulator output power and lowering the machine excitation until the alternator voltage returns to
its regulated value. i ‘I

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Section 2. Inspection / Check
1. Inspection of Voltage Regulator

a. General i ;I
lnspect’the voltage regulator periodically, at the same time other inspections of the generator set
are made.
b. Inspect Connectors and Terminals
(I) Inspect connectors for full engagement.
(2) Inspect terminals for security.
c. Inspect Wiring
Inspect wire insulation for cracks and damage.
d. Inspect Attaching Parts
Inspect attaching hardware for security
e. Inspect regulator fuse.
When replacing this fuse, replace it with the EXACT SAME type and rating of fuse.
2. Check of Voltage Regulator

a. General
Refer to the list of electrical checks following the troubleshooting chart in Section 3-1. These
checks may be performed to locate defective components in the regulator. Use the list in
conjunction with the schematic and connection diagrams at the end of this manual.
The operating voltages in the list of electrical checks were observed when the regulator was
supplying two amperes of direct current to the generator exciter fields. This current value may be
different for some installations of the regulator and, consequently, the voltage check values may
vary.
b. Conditions for Check
(11 The generator must have no load (other than the regulator)
(2) The voltage regulator must be regulated at 120 volts, with four-wire, three-phase voltage at
400-Hz.
(3) A Triplett No. 630 volt-ohmmeter, or equivalent, is recommended for measuring the voltages.
January 20194 Revised Section 2-2

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Section 3. Adjustment and Test
1. Adjustment Procedures ,
a. General i 6
When a voltage regulator is first put into service, or when output (generator-to-aircraft) cables are
changed, the regulator may require as many as five separate adjustments. The five adjustments I
are for (1) generator output voltage value, (2) cable length line drop compensation, (3) cable size
line drop compensation, (4) “rate” adjustment, and (5) “damp” adjustment. See Figure 1 for
identification of components used for regulator adjustment.
b. Adjust generator output voltage.
Perform this adjustment with the generator set operating at rated speed with no load applied.
Rotate the rheostat knob (1) CLOCKVVlSE to INCREASE voltage and COUNTERCLOCl$WlSE to
DECREASE voltage. Observe the AC voltmeter and adjust output voltage to 115 V AC.
c. Adjust Line Drop Compensation for Cable Length
Adjustment of line drop compensation magnitude is made with the knob marked “Foot
Compensation” (2) on the line drop compensation module. The knob dial is calibrated for
approximate cable length in feet. The “Foot Compensation” knob controls a rheostat which limits
the current flowing in the compensation circuit. The setting of the rheostat resistance determines
the magnitude of the compensation. Rotating the knob clockwise increases the magnitude of the
compensation, and rotating it counterclockwise decreases the magnitude. To adjust the line drop
compensation gain, proceed as follows:
(7) Connect the generator output cables to a balanced, three-phase load of 30 kilowatts.
(21 Make sure that the line drop compensation switch (4, Fig.1) is in the ON position.
(3) Set the “Foot Compensation” knob to a dial setting corresponding to the length of the output
cables being used.
d. Adjust Line Drop Compensation for Cable Size
The compensation circuit must be adjusted to match not only the voltage drop in the power cables
to the load, but must be adjusted to match the phase of the voltage drop. This is done by adjusting
the relative magnitude of the reactive and resistive compensation with the “Cable Size” knob (3).
This knob is calibrated in cable sizes and controls a varied resistance in series with a fixed
reactance. The power factor of the compensation circuit is varied by varying the resistance and
leaving the reactance constant. Rotating the knob clockwise increases the resistive component of
the compensation circuit and simulates a smaller cable. Rotating the knob counterclockwise
decreases the resistive component of the compensation. Adjust line drop compensation phase as
follows:
(7) Set the “cable size” knob (3) to a dial setting corresponding to the size of the output cables.
(2) Re-adjust the generator voltage control (1) to the desired value if the line drop compensation
adjustments have affected the no-load voltage output.
(3) Load the machine with the largest available three-phase load of rated power factor not
exceeding the maximum rating of the machine. If the load voltage rises or drops more than one
percent (1%) at the load end of the cables, decrease or increase the setting of the load “Foot
Compensation” knob until the regulation is flat.

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TM-759 / Operation-and Maintenance Manual
(4) Load the machine with the largest available three-phase unity power factor load within the rating
of the machine. If the voltage rises or drops more than one percent (1%) at full load, adjust the
“Cable Size” setting until flat regulation is obtained. If it is necessary to adjust the cable size
setting, repeat step (3) above.
e. Adjust Damping Gain
The gain adjustment for the damping circuit is a 1500 ohm variable resistance (R551) in series with
the primary winding of the dampiqglvansformers. This resistor is in the form of a screwdriver-
adjustable potentiometer (7) with a locking nut, located on the right side of the end of the sensing
andd preamplifier assembly. Turning the potentiometer screw clockwise increases the resistance,
decreasing the system damping, and making the regulator less stable. Turning the adjustment
screw counterclockwise decreases the resistance, improving regulator stability, but slowing
regulator-response. This resistance is set at the factory for satisfactory response times, and should
not ordinarily require adjustment. However, if adjustment becomes necessary, proceed as follows:
(1) Loosen the potentiometer adjusting screw locknut.
(2) Connect the generator output to a balanced, three-phase load of 30 kilowatts.
(3) With generator running at 115-V AC no load, operate the contactor “on-oft” switch on the engine
control panel.
(4) Turn the adjusting screw counterclockwise with a screwdriver to improve generator output
stability.
(5) Turn the adjusting screw clockwise to decrease regulator response time. Best adjustment is
approximately 314 of full travel clockwise.
(6) Tighten the locknut securely after the adjustment has been completed.
f. Adjust Damping Rate
The rate adjustment is a potentiometer (8, Fig. 1) is a potentiometer connected across the
secondary oo the damping transformer. Both the amplitude of the damping signal and its phasing
are affected by this potentiometer. Because of this, a relatively large change in system
performance is obtained with a relatively small change in its setting. When the screw is turned fully
counterclockwise, the amplitude of the damping signal fed into the transistor preamplifier is at a
minimum. When the screw is set fully clockwise, the signal is at maximum. The system may be
unstable with this potentiometer set at either maximum or minimum because of the phase shift. The
potentiometer is set and locked at the factory for good system transient response and should not
need further adjustment. If the potentiometer does need adjustment, proceed as follows:
(7) Loosen the adjusting screw locknut.
(2) With a dcrewdrlver, turn the adjusting screw to near its full counterclockwise position.
(3) Turn the adjusting screw slowly clockwise while observing generator output voltage on the
generator voltmeter. The generator output voltage will oscillate until a certain point of
adjustment is reached, at which it will abruptly become steady. The best adjustment for the
systemwill usually be reached when the screw is turned just slightly (5’ to 10’) beyond this point
in a clockwise position.
(4) Tighten the locknut securely after the adjustment has been completed.

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1. Voltage adjusting rheostat

2. Cable length
compensation rheostat
3. Cable size compensation
rheostat
4. On-Off switch, line-drop
compensation
5. Fuse (5-amp)
6. Fuseholder
7. Damping gain
potentiometer
8. Damping rate
potentiometer
Voltage Regulator
Adjustments
Figure 1
2. Test the Voltage Regulator

After necessary adjustments have been completed, test the regulator as follows:
a. Connect a voltmeter at the load end of the generator output cables.
b. Operate the machine at no load and observe voltage reading.
c. Operate the machine under load and observe voltage reading. Voltage under load and no
load should vary no more than 1% at the load end of the cables.
NOTE: The panel mounted voltmeter will indicate a higher voltage than indicated by a voltmeter at the
load end of the output cables. The amount of variance will depend upon cable length and size.

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TM-759 / Operation’and Maintenance Manual
DAMP*(Gain) -Affects response

and stability
14
I
When this screw is turned
@
CLOCKWISE, regulator becomes
MORE RESPONSIVE, LESS STABLE
,
When this screw is turned
08 08 COUNTERCLOCKWISE, regulator
R10 R14
becomes MORE STABLE (steadier),
RATE DAMP
LESS RESPONSIVE
Best adjustment is
approximately 3/4 of full
travel clockwise
RATE (Affects stability)

:
Regulator will likely be unstable
if adjusting screw is at either
limit of adjustment CLOCKWISE
or COUNTERCLOCKWISE. From a
point near full COUNTERCLOCK-
WISE position, turn the screw
CLOCKWISE until a point Is
reached where the voltage
regulator abruptly becomes
STEADY. Best adjustment for
the system Is usually 5’ to
IO0 beyond this point in a
CLOCKWISE direction.
Voltage Regulator Damping Adjustments

Figure 2

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Section, 4. Cleaning and Repair
1. Removal of Voltage Regulator

It is recommended that the volt&e, regulator be removed from its mounted position and placed on a
workbenah before any removal of components is attempted, with the exception of the fuse, fuseholder,
etc., which are easily accessible. To remove the regulator, proceed as follows.
a. Disconnect the main nineteen pin connector (1-I; 14, Fig. 1).
b. Remove the regulator attaching hardware and excercise care to avoid dropping the unit.
c. Place the unit on a clean workbench
2. Removal of Regulator Main Components and Subassemblies

There are no special instructions required for removal of regulator main componets. Use standard
electrical industry practices.
3. Cleaning
Electric shock can kill! Remove power before cleaning regulator.
A. Make certain that compressed air is clean and dry.
B. Do not use flammable or conductive cleaners.
C. Exercise care to avoid damage to components.
Under normal operating conditions, very little cleaning is required; however, when operating under
dusty conditions, it may be necessary to periodically clean the regulator with compressed air.
4. Repair
For the convenience of maintenance personnel, this voltage reguiator is designed to be trouble-free
and simple to put back into service once it has malfunctioned or if it is not functioning properly. Flight
line repair is usually limited to removal and replacement of the entire voltage regulator assembly, and
adjustments of the newly-installed voltage regulator if necessary.
For customers that have facilities that permit repair of voltage regulators, the regulators may be
repaired according to malfunctions disclosed through troubleshooting. When making repairs, proceed
as follows:
a. After using the troubleshooting chart and the electrical check chart in Section 3-l to locate defective
parts, removing the unit from the ground power unit, and placing it on the workbench, disassemble
the regulator as required to reach the part to be replaced.
b. Remove the part(s) found to be defective in step A. above, and install new part(s).

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5. Installation of Regulator Main Components and Subassemblies

a. Reassemble and reinstall the voltage regulator. Reassemble regulator components in accordance
with good industry practices, making certain that all electrical connections are tight and all attaching
hardware is securely installed.
b. Adjust, if required, in accordance with adjustment procedures in Section 2-3.
Section 2-4 January 20/94 Revised

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Chapter 3. Troubleshooting
Section 1. Troubleshooting Procedures
1. General
Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the
exact cause is located. When looking for the cause of a trouble in a circuit or system begin at the
source of power or supply. Continue testing and checking the voltage regulator, step-by-step, in an
orderly manner, until the cause of trouble is located.
2. Troubleshooting Chart
a. Description
The troubleshooting chart lists information under three headings as follows:
(71 Trouble, Symptom, and Condition
(2) Test or Inspection
(31 Corrective Action
b. Use of the Troubleshooting Chart
The troubleshooting chart that follows is furnished to provide maintenance and repair personnel with
a time-saving guide for locating trouble. To use the chart, proceed as follows:
(7) Locate the symptom(s) of trouble in the “Trouble, Symptom and Condition” column.
(2) Check the probable causes of trouble in the “Test or Inspection” column.
(3) Test, check, repair, or correct the trouble as indicated in the “Corrective Action” column.
If the cause of a trouble is an uncommon one and cannot be located by use of the chart, start at the
source of power or supply and check the affected circuit or system completely. Use schematic and
connection diagrams supplied with this manual.
Electrical components mentioned in the troubleshooting chart are identified by a noun name and a
corresponding symbol which allows the user to identify the item more easily on schematic diagrams.
It is assumed that wiring and connections in defective circuits have been thoroughly checked before
condemning any other components.
NOTE: Reference symbols (S9, etc.), used in the Troubleshooting Chart, are identified on Schematic
and Connections Diagrams at the end of this manual.
Following the troubleshooting chart is a list of electrical checks which may be performed to locate
defective components in the regulator. Use the list in conjunction with the schematic and
connection diagrams at the end of this manual.
The operating voltages in the list of electrical checks were observed when the regulator was
supplying two amperes of direct current to the generator exciter fields. This current value may be
different for some installations of the regulator and, consequently, the voltage check values may
vary.
January 20194 Revised Section 3-I

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Trouble, Symptom & Condition Test or Inspection Corrective Action
1. Generator voltage will not build a. Fuse (Fl) open. Replace fuse.
up to normal.
b. Shorted or open diode Replace the shorted diode.
i ; (CR531 through C534).
.I c. Exciter field circuit shorted Repair as necessary.
or grounded.
d. Sensing and pre-amplifier Connect plug.
plug (P503 or P504) not
connected.
e. Generator field circuit open Restore continuity to field circuit.
f. Generator field circuit Replace defective resistor.
ballast resistor open.
g. Voltage build-up circuit Replace relay. ’
relay (K501) normally-
closed contacts open.
h. Generator residual voltage “Flash” exciter fields with 12-V
too low, or reversed. DC from a separate storage
battery. CAUTION: DO NOT
GROUND EITHER BATTERY
TERMINAL. DAMAGE TO
REGULATOR WILL OCCUR
AS SOON AS POWER IS
PRODUCED BY THE
GENERATOR
2. Generator voltage builds up a. Voltage reference diode Replace diode.
until relay. actuates, then falls (VR501) shorted.
back.
b. Pre-amplifier transistor Replace transistor.
(Q501 or Q502) shorted
c. ~re-;e;lplifrer diode (VR502) Replace diode.
d. Stability capacitor (C507) Replace capacitor.

shorted
3. Generator voltage builds to a a. Voltage build-up relay: Replace relay.
dangerously high level. 1. Coil open
Flashing relay does not 2. Contacts “welded”
actuate.
b. Line-drop coupling plug Connect plug securely.
(P502) not in socket.
c. Sensing diode (CR501, Replace diode and check
CR502, CR503) shorted. sensing transformers for
damage.
d. Voltage build-up resistor Replace resistor.
(R512) open
Troubleshooting Chart
Figure 1 (Sheet 1 of 3)

Page 3
c .
4. Generator voltage builds to a a. Magnetic amplifier reactor Replace reactor.

dangerously high level; (L505) winding open.
flashing relay actuated, but
voltage is not controllable with
voltage adjusting potentio- i iI
meter. .I
b. Damping potentiometer Replace potentiometer
(R572) open.
c. Voltage comparison Restore continuity.
potentiometer (R571) circuit
open.
d. Voltage comparison resistor Replace resistor.
(R509) open.
e. Voltage comparison Replace diode.
reference diode (VR501)
open.
f. Pre-amplifier capacitor Replace capacitor.
(C505) shorted
g. Pre-amplifier transistor Replace transistor.
(Q501, Q502) open.
h. Pre-amplifier resistor (R507 Replace resistor.
or R511) open.
i. Pre-amplifier diode Replace diode and check
(CR514) shorted. transformers (T501, T502,
T503) for damage.
5. Poor voltage regulation when a. Voltage comparison resistor Replace resistor
generator is loaded (droop at (R506 or R508) open.
regulator input terminals more
than 1%).
b. Voltage sensing choke Replace choke.
(L501, L502, L503 or L504)
partially shorted.
c. Voltage sensing diode Replace diode.
(CR501 through CR509)
open.
d. Voltage comparison Replace diode.
reference diode (VR501)
has high dynamic
resistance.
e. Pre-amplifier transistor Replace transistor.
(Q501 or Q502) low gain.
Figure I (Sheet 2 of 3)

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c .
6. Generator voltage unstable. a. Damping transformer Replace transformer.

(T504) open.
b. Damping rheostat (R551) Adjust or replace rheostat.
; incorrectly adjusted or open.
i !
I c. Damping resistor (R510) Replace resistor.
open.
d. Damping potentiometer Check continuity. If good,
(R572) incorrectly adjusted adjust. If not, replace
or open. potentiometer.
7. Voltage of one phase rises a. Voltage detection resistor Replace resistor.
above 130 volts, (R502) open.
line-to-neutral, with
unbalanced load.
b. Voltage detection trans- Replace transformer.
former (TSOI , T502, T503)
coils shorted or open.
c. Voltage detection choke Replace choke.
(L502, L503, L504) coil
open.
d. Voltage detection diode Replace diode.
(CR51 1, CR512, or CR51 3)
shorted.
6. Generator voltage becomes a. Voltage detection diode Replace diode and trans-
erratic. Smoke comes From (CR501 through CR509) former-s (T501, T502, and T503).
voltage detection transformers. shorted.
b. Voltage detection capacitor Replace capacitor and trans-
(C501 thru C504) shorted. formers (T501, T502, and T503).
. d
Figure 1 (Sheet 3 of 3)
c. Checking the Voltage Regulator

(1) General
The following pages provide electrical checks which may be performed to locate defective
components in the regulator. Use the list in conjunction with the schematic and connection
diagrams at the end of this section.
(21 Conditions for Check
a. The generator must have no load other than the regulator.
b. d;h v$tage regulator must be regulated at 720 volts, with four-wire, three-phase voltage at
- .
c. A Triplett NO.630 volt-ohmmeter or equivalent is recommended for measuring voltages.
NOTE: The operating voltages listed in the chart were observed when the regulator was supplying two
amperes of direct current to the generator exciter fields. This current value may be different for
some installations of the regulator and, consequently, the voltage check values may vary slightly.

Page 5
.
) Reference Location for
Designator Component Voltage Measurement Voltage Value
c501 Capacitor, 3mF, SO-Volt Across Capacitor 16.0 V-DC
c502 Capacitor, 3mF, 50-Volt Across Capacitor 12.5 V-DC
c503 Capacitor, 3mF, 50-Volt Across Capacitor 12.5 V-DC
c504 * Capacitor, 3mF, 50- o,lt ’ Across Capacitor 12.5 V-DC
Y
c505 Capacitor, 20mF, 50-V& Across Capacitor 0.58 V-DC
C506 Capacitor, 20mF, 50-Volt Across Capacitor 5.4 V-DC
c507 Capacitor, 20mF, 50-Volt Across Capacitor Too low to read
CR501 Diode, 1N4820 Across Diode 16.8 V-DC
CR505 Diode, 1N4820 Across Diode 13.0 V-DC ,
CR51 1 Diode, 1N4820 Across Diode 0.60 V-DC
CR51 4 Diode, 1N4820 Across Diode 3.80 V-DC
CR51 5 _ Diode, lN4820 Across Diode 7.2 V-DC
CR531 Diode, S2040 Across Diode 33 V-DC
CR533 Diode, S2040 Across Diode 33 V-DC ’
K501 Relay Across Relay Coil 13-O V-DC
L501 Choke, 1CZ-63 Across Choke Coil 0.60 V-DC
L502 Choke, lCZ-63 Across Choke Coil 0.60 V-DC
L505 Reactor Across Winding l-2 140 V-AC, 0.4 V-DC
Across Winding 3-4 140 V-AC, 0.4 V-DC
Across Winding 5-6 6.0 V-AC, 0.38 V-DC
Across Winding 7-8 11V-AC
L506 Choke, Line Drop Across Choke Coil 0.70 V-DC
Q501 Transistor, 2N3904 Emitter to Base 0.55 V-DC
Base to Collector 9.2 V-DC
Emitter to Collector 9.8 V-DC
Section 3-I January 20/94 Revised

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Reference Location for

Designator Component Voltage Measurement Voltage Value
Q502 Transistor, MM4007 Emitter to Base 0.55 V-DC
Base to Collector 12.0 V-DC
Emitter to Collector 12.6 V-DC
R501 Resistor, 150-Ot/m j 5-Watt Across Resistor 1.8 V-DC
R502 ’ Resistor, 1OOO-Ohm,5-Watt Across Resistor 12.5 V-DC
R503 Resistor, 1OOO-Ohm,5-watt Across Resistor 12.5 V-DC
R504 . Resistor, 1OOO-Ohm,5-watt Across Resistor 12.5 V-DC
R505 Resistor, 1OOO-Ohm,S-watt Across Resistor 12.5 V-DC
R508 Resistor, 470-Ohm, l/2-watt Across Resistor 6.0 V-DC
R509 Resistor, 500-Ohm, 5-watt Across Resistor 3.0 V-DC ’
R510 Resistor, 1OOO-Ohm,25-watt Across Resistor 65 V-AC, 44 V-DC
R511 Resistor, 1OO-Ohm,5-Watt Across Resistor 3.4 V-DC
R512 Resistor, 47-Ohm, l-Watt Across Resistor 7.2 V-AC, 3.3 V-DC
R513 Resistor, 1OOO-Ohm,in-Watt Across Resistor 7.2 V-DC
R514 Resistor, 470-Ohm, l/2-Watt Across Resistor 0 V-DC
R551 Rheostat, 1500-Ohm, 25-Watt Across Rheostat 20 V-AC, 15 V-DC
R553 Rheostat, (Triple Tandem)
1O-Ohm, 25-Watt Across Rheostat 0.15 V-AC
R554 Rheostat, (Triple Tandem)
250-Ohm, 25-Watt Across Rheostat 0.55 V-AC
R571 Potentiometer, 750-Ohm, 2-Watt R509 End to Slider 2.4 V-DC
R506 End to Slider 0.7 V-DC ’
Across Potentiometer 5.9 V-AC
R572 Potentiometer, 2500-Ohm, 25-Watt Slider to end of R571 Too Low to Read
Across Potentiometer 3.4 V-DC
T501 Transformer, High Phase Green to Black 120 V-AC
Red to Orange 30 V-AC
Red to Blue 15 V-AC
Red to Blue 15 V-AC
Red to Blue 15 V-AC
T504 Transformer, Damping Orange to Blue 6.0 V DC
Red to Brown 11.0%AC, 1.1 V-DC
VR501 Diode, Zener, 6.2~Volt, I-Watt Across Diode 6.1 V-DC
VR502 Diode, Zener, 80-Volt, l-Watt Across Diode 0.25 V-DC
January 20194 Revised Section 3-I

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Chapter 4. Illustrated Parts List

i ;,
Section 1 Introduction
q
1. Scope
The Illustrated Parts List identifies, describes, and illustrates all components of the Static Voltage
Regulators, Hobart Part Numbers 430391 B, 430391C, and 281407 with the exception of attaching
hardware.
2. Purpose
The purpose of the Illustrated Parts List is to provide maintenance and provisioning personnel with
identification and descriptive data for use in the provisioning, requisitioning, storing, and issuing of
spare parts.
3. Arrangement
Chapter 4 is arranged as follows:
Section 1 - Introduction Section 3 - Parts List
Section 2 - Manufacturers’ Codes Section 4 - Numerical Index
4. Explanation of Parts List Form

This form is divided into five columns. Beginning at the left side of the form and proceeding to the right,
columns are identified as follows:
a. Contents
The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail
parts. All parts of the equipment are listed except:
(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are
available commercially.
(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available
(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to
other parts, weldments, or assemblies.
b. Parts List Form
(1) “FIGURE/ITEM NO.” Column

This column lists the figure number of the illustration applicable to the list and also identifies
each part in the illustration by an item number which appears on the illustration. Assemblies and
subassemblies which are illustrated in their disassembled state will not be identified by an item
number.

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(2) “HOBART PART NUMBER” Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part
is a purchased item, the vendor’s identifying fivedigit code and his part number will appear in
the “NOMENCLATURE” column. Vendor parts which are modified by Hobart Brothers will be
identified as such in the “NOMENCLATURE” column. In case Hobart Brothers does not have
an identifying part number for a purchased part, the “HOBART PART NUMBER” column will
reflect “NO NUMBER” and the vendor’s mumber will be shown in the “NOMENCLATURE”
column. Parts manufactured by Hobart Brothers reflect no vendor code or vendor part number
in the “NOMENCLATURE” column.
(3) “NOMENCLATURE” Column
The item identifying name appears in this column. The indenture method is used to indicate item
relationship. Thus, components of an assembly are listed directly below the assembly and
indented one space. Vendor codes and part numbers for purchased parts are shown in this
column. Hobart modification to vendor items is also noted in this column.
(4) “EFF” (Effectivity) Code
Code letters (“A’; “B’; “Cl; etc.) are used in this column to indicate the use of parts where more
than one model or type of machine is covered by the parts list.
Parts Coded ‘A” are usable on Part No. 430391 B only.
Parts Coded “B” are usable on Part No. 430391C only.
Parts Coded “c” are usable on Part No. 281407 only.
(5) “UNITS PER ASSEMBLY” Column
This column indicates the quantity of parts required for an assembly or subassembly in which the
part appears. This column does not necessarily reflect the total used in the complete end item.

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Section 2. Manufacturers, Codes
1. Explanation of Manufacturers’, Code List

The following list is a compilationloflvendor codes with names and addresses for suppliers of
purchased, parts listed in this publication, The codes are in accordance with the Federal Supply Codes
for Manufacturers’ Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes are
inserted in the nomenclature column of the parts list directly following the item name and description. In
case a manufacturer does not have a vendor code, the full name of the manufacturer will be listed in
the nomenclature column.
Code Vendor’s Name And Address
01746 Electronics Engineers, Inc., 5615 Division, Chicago, Illinois 60651
02660 Amphenol Corporation, 2801 S. 25th Avenue, Broadview, Illinois 60153
15605 Cutler-Hammer, 1391 W. St. Paul Avenue, Milwaukee, Wisconsin 53223
44655 Ohmlte Manufacturing Co., 3601 W. Howard St. Skokie, IL 60076
50508 Magnetic Components, Inc., 9520 Ainslie St., Schiller Park, IL 60176
71400 Bussmann Manufacturing, Division of McGraw-Edison Company, ,

2536 W. University Street, St. Louis, Missouri 63017
77342 Potter & Brumfield Division, AMF Company, 1200 E. Broadway,

Princeton, Indiana 47570
96682 Genisw Technology Corporation, 18435 Susana Road,

Compton, California 90221

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Section 4-2 January 20/94 Revised

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Section 3. Parts List
1. Explanation of Parts List Arrangement

The parts list is arranged so that thb illustration will appear on a left hand page and the applicable parts
list will appear on the opposite right hand page. Unless the list is unusually long, the user will be able
to look at the illustration and read the parts list without turning a page.
NOTE:An item which does not reflect an index number is an assembly which is not illustrated in its
assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.
2. Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.
* - item not illustrated
A, or AMP - ampere
AC - alternating current
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
Hz - Hertz (cycles-per-second)
I.D. - inside diameter
IN - inch
kVA - kilovolt-ampere
F - microfarad
No. - number
NHA - next higher assembly
i2 - Ohm
OM - Owners Manual
PRV - peak reverse voltage
PSI - pounds per square inch
Ref - reference (the item has been listed previously)
TM Technical Manual
T-R - transformer-rectifier
V - volt (when used as a prefix to a five-digit number, indicates vendor code)

Page 1
Magnetic Amplifier Voltage Regulators t4oBARr
GROUND POWER
volraqe Kequlator Assembly

Part Numbers 430391B and 430391C
Figure 1
Section 4-3
Page 2 January 20194 Revised
-
NOMENCLATURE UNIT3
FIGURE HOBART AIRLINE per
ITEM NO. PART NO. PART No. 1234567 EFF ASSY
l- 430391 B REGULATOR, VOLTAGE (MAG-AMP)

(For NHA See Fig. 3) A RE
430391 c ’ 1 REGULATOR, VOLTAGE (MAG-AMP)
I B
(For NHA See Fig. 3) RE
430472A . CHASSIS, SENSING & PRE-AMP, ASSEMBLY 1
1CZ-63 . . REACTOR, FILTER, HIGH PHASE, V50508
No. E3661-A 4
430473 PANEL, CHASSIS 1
402358 : : NAMEPLATE, ADJUST 1
1cz-60 . . TRANSFORMER, DAMPING, V50508
No. E3196-A 1
402563-3 HOUSING, PIN CONNECTOR 1
401563-2 : : HOUSING, PIN CONNECTOR 1
400698-2 . . POTENTIOMETER, 2500-OHM. 2-WATT.
V44655, No. CLU-2521 1
8 w-971 2-30 RHEOSTAT, 1500-OHM, 25-WAlT,
* ’ V44655, No. H 1
9 402357 . . TRANSFORRMER, HIGH PHASE,
50508, No. 40-8587
10 485053 BOARD, PC, HIGH PHASE SENSING 1
11 485283 : : BRACKET, MOUNTING, PC BOARD, REAR 1
12 404460-l SUPPORT, PC BOARD, LOCKING 3
13 485282 : : BRACKET, MOUNTING, PC BOARD, FRONT 1
14 79B-1140 . . RELAY, V77342, No. KHU17Dll 1
15 79A-1142 . . SPRING, RETAINING, RELAY,V77342 ’ 1
16 430341 . . BRACKET, MOUNTING, CHASSIS 1
430340 . CHASSIS, LINE DROP COMPENSATION

ASSEMBLY 1
17 430470 . . CHASSIS 1
18 1cz-97 REACTOR, LINE-DROP, V86151, No. E3963 3
19 480725 : : LABEL, INSTRUCTION 1
20 402563-3 HOUSING, PIN CONNECTOR 1
21 1cz-105 : : RHEOSTAT, TRIPLE TANDEM,
V44655, No. H-l O-F2-T3 1
22 1CZ-128 . . RHEOSTAT, TRIPLE TANDEM,
V44655, No. 6610 1
23 1cz-70 . . SWITCH, ON-OFF, V15605, No. 761OK2 1
24 402373 . . NAMEPLATE, LINE DROP COMPENSATION 1
25 W-l 1597 . . KNOB, POINTER, V75376, No. S-292-3L 2

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Page 4
NOMENCLATURE UNIT
FIGURE HOBART AIRLINE per
TEM NO. PART NO. PART No. 1234567 EFF ASS’
l- (Continued
26 430530 i i, :’ CHASSIS, REGULATOR 1
27. y-9712-13 RHEOSTAT, REGULATOR, 750-OHM,
25-WATT, V44655, MODEL H 1
28 30GH-734 BRACKET, MOUNTING, RHEOSTAT 1
29 HF-745 : : NAMEPLATE 1
30 16DA-2162 . . KNOB, RHEOSTAT, V44655, No. 5150 1
31 430476 INSULATION, BOTTOM, RESISTOR 1
32 W-9746-9 : : RESISTOR, V44655, No. 0205 1
33 1cz-74 INSULATOR, TOP, RESISTOR 1
34 402342 : : REACTOR, REGULATOR, V96682,
No. 70-8532 1
35 401911-3 . . TERMINAL BOARD, V88223, No. 441-3 1
36 W-l 0827-8 RESISTOR, 470-OHM, l/2-WATT 1
37 370141 : : BRACKET, MOUNTING, PLUG 1
38 25MS-328 . . SPACER 2
39 400782-l . . FUSE, 5-AMP, FAST-ACTING, GLASS
TUBE, MTH 1
40 HF-2407 FUSEHOLDER, V71400, No. HKP 1
41 402376 : : RECEPTACLE, VO2660, No. MS-1302A-22-14P 1
*42 401564-2 . . HOUSING, SOCKET CONNECTOR 1
*43 401564-3 . . HOUSING, SOCKET CONNECTOR 2
* Not Illustrated

Page 5
Voltage Regulator Assembly

Part No. 281407
Figure 2

Page 6
l4omAm=
GROUND POWER
NOMENCLATURE UNIm
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASS’r
2- 281407 REGULATOR, VOLTAGE, ASSEMBLY c 1

1 281399 .‘CHASSIS, REGULATOR c 1
2’ 402342 i ;, . REACTOR, REGULATOR, 800 VA 1
3 4iO476 . INSULATOR, BOTTOM, RESISTOR 1
4 W-9746-9 . RESISTOR, 1OOO-OHM,25WATT,
V44655, No. 0205 1
5 1a-74 INSULATOR, TOP, RESISTOR 1
6 401911-3 : STRIP, TERMINAL, V88223, No. 441-3 1
7 HF-745 . NAMEPLATE, REGULATOR RHEOSTAT 1
8 w-9712-13 . RHEOSTAT, REGULATOR, 750-OHM, 25-WATT,
V44655, MODEL H, l-Turn 1
9 16DA-2162 KNOB, RHEOSTAT 1
10 281401 : BRACKET, MOUNTING, RHEOSTAT c 1
11 401564-3 HOUSING, CONNECTOR 2
12 430340 : CHASSIS, LINE-DROP COMPENSATOR * 1
13 401564-2 . HOUSING, CONNECTOR 1
14 370141 . BRACKET, MOUNTING, PLUG 1
15 HF-2407 . FUSEHOLDER, V71400, No. HKP 1
16 400782-I FUSE, 5-AMP, TYPE MTH 1
17 402376 : RECEPTACLE, AMPHENOL, 1g-CONTACT,
VO2660, No. MS-1302A-22-14P 1
18 480725 LABEL, INSTRUCTION, REGULATOR 1
19 430472A : CHASSIS, SENSING & PRE-AMP ASSEMBLY * 1
20 W-l 0827-8 RESISTOR, 470-OHM, l/2-WATT 1
21 400830-l 5 : TERMINAL RING-TONGUE ’ 2
*22 181760 . NAMEPLATE, MODEL SERIAL NUMBER 1
*Not Illustrated
** Refer to this assembly in Figure 1 for parts breakdowrl

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Page 8
l+oBAlm
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Section 4. Numerical Index
1. Explanation of Numerical Index

The.purpose of this index is to as&s\ the user in finding the figure number and description of a part
when the part number is known. Part numbers are arranged in alpha-numeric sequence. Thus, any
part beginning with the letter “A” would be located before any part beginning with the number “1 .‘I. The
figure and item number of the part is directly opposite the part. If the part is used more than once, each 1
location is listed, commencing with the first.
PART NUMBER FIGURE-ITEM No.
HF-2407 l-40,2-15
HF-745 i-29,2-7
W-l 0827-8 l-36,2-20
W-l 1597 1-25
w-971 2-l 3 l-27,2-8
W-9746-9 l-32,2-4
W-971 2-30 1-8
1cz-105 1-21
1CZ-128 l-22
1CZ-60 l-4
1CZ-63 l-l
1cz-70 1-23
1cz-74 . l-33,2-5
1cz-97 1-18
16DA-2162 l-30,2-9
181760 2-22
25MS328 1-38
281399 2-1
281401 2-10
281407 2-o
30GH-734 1-28
370141 1-37,2-l 4
400698-2 1-7
400782-I ‘l-39,2-16
400830-l 5 2-21
401563-2 l-6
401563-3 l-5,1-33
401564-2 l-42,2-13
401564-3 1-43,2-l 1

Page 1
140BAmm
GROUND POWER
PART NUMBER FIGURE-ITEM No.
401911-3 l-35,2-6
402342 . l-34,2-2
402357 1-9
402358 I 1 1-3
402373 , 1 'I 1-24
402376 l-41,2-17
402563-3 l-5,1-20
404460-I 1-12
430340 l-16,2-12
430341 1-16
4303918 1-o
430391 c 1-o
430470 1-l-17
430472A i-20,2-19
430473 l-2
430476 l-31,2-3
430530 1-26
480725 l-19,2-18
485053 l-10
485282 1-13
485283 . l-11
485530 1-26
79A-1142 I-15
798-1140 1-14

Page 2
HoBARr
GROUND POWER
Chapter 5. Manufacturer’s Literature

i6
Hobart Diagrams
485318 Diagram, Schematic, Voltage Regulator 430391 B
485318A Diagram, Schematic, Voltage Regulators 430391 C and 281407
485319 Diagram, Connection, Voltage Regulator 430391 B
485319A Diagram, Connection, Voltage Regulator 430391 C
281402 Diagram, Connection, Voltage Regulator 281407
January 20194 Section 5-O

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Section 5-O January 20194

Page 2
t+oBAm=”
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: -
----- ------- ---- --_ :
I ,-JLqqij; 2f---:[---pz’i ------ a
Schematic Diagram 485318,

for Voltage Regulator 430391 B
Figure 1

Page 314
i’, ’
_--. -.___ _
lAoBAm=
GROUND POWER
Connection Diagram 485319A,

for Voltage Regulator 430391 C
Figure 4

Page 9110
-L
n
iI b-
L50.3 1
--- I ’
I
A I
--- ----- -------
P505 P506 J506
P507 J507
5A 1
l4oBAlm
GROUND POWER
Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The
specific local environments may ;dependent upon conditions beyond the manufacturer’s control. The
manufacturer should be consulte %”ifbny unusual conditions of use exist which may affect the physical
condition or operation of the equipment. Among such conditions are:
a. Exposure to:
(I) Combustible, explosive, abrasive or conducting dusts.
(2) Environments where the accumulation of lint or excessive dirt will interfere with normal
ventilation.
(3) Chemical fumes, flammable or explosive gases.
(4) Nuclear radiation.
(5) Steam, salt-laden air, or oil vapor.
(6) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth.
(7) Abnormal shock, vibration or mechanical loading from external sources during equipment
operation.
(8) Low and/or high ambient temperatures.
b. Operation at:
(7) Voltages above or below rated voltage.
(2) Frequency other than rated frequency.
(3) Unbalanced voltages.
(4) Operation at loads greater than rated.
c. Operation with:
(7) Parts or elements unauthorized by the manufacturer.
(2) Unauthorized modifications.
d. Operation in poorly ventilated areas.
January 20194 Revised Unusual Service Conditions

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TM-759

OPERATION AND MAINTENANCE MANUAL

HOBART BROTHERS COMPANY

This page intentionally leil blank.

Unusual Service Conditions January 20/94 Revised

ELECTRIC SHOCK can KILL. Do not touch live electrical parts.

Safety Instructions 910082 Sept l/90 Page i

2. Fire And Explosion Prevention

3. Toxic Fume Prevention

4. Bodily Injury Prevention

5. Medical and First Aid Treatment

Page ii Safety Instructions 910082 Sept II90

IF BREATHI G IS DIFFICULT, give oxygen, if available, and have victim lie

6. Equipment Precautionary Labels

Safety Instructions 910082 Sept l/90 Page iii

Page iv Safety Instructions 910082 Sept l/90

SUBJECT CHAPTER/SECTION PAGE

SECTION 2. INSTALLATION AND PREPARATION FOR USE ,

January 20194 Table of Contents

Table of Contents (Continued)

SUBJECT CHAPTEFUSECTION PAGE

SECTION 1. SEQUENCE AND THEORY

SECTION 3. ADJUSTMENT AND TEST

SECTION 4. CLEANING AND REPAIR

Table of Contents January 20194

Table Of Contents (Continued)

SECTION 1. TROUBLESHOOTING PROCEDURES

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 2.Manufacturer’s Codes

SECTION 3. PARTS LIST

SECTION 4. NUMERICAL INDEX

CHAPTER 5. MANUFACTURERS’ LITERATURE

January 20194 Table of Contents

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Table of Contents January 20194

January 20/94 Revised Introduction

This page intentionally lei7 blank

Introduction January 20/94 Revised

January 20/94 Revised Section l-1

1. Resistor 11. Receptacle connector

Magnetic Amplifier Voltage Regulator

Section 1-l January 20194 Revised

3. Detailed Circuit Descriptions

January 20194 Revised Section l-l

d. The Power Stage Full-wave, Single-phase Magnetic Amplifier

Section l-1 January 20/94 Revised

g. The Voltage Build-Up Circuit

January 20194 Revised Section l-1

This page intentionally lei? blank.

Section I-1 January 20194 Revised

Section 2. Installation And Preparation For Use

2. Preparation for Use

January 20194,Revised Section l-2

VOLTAGE REGULATOR CONNECTION DIAGRAMS

FOR VOLTAGE REFER TO

Section 1-2 January 20194 Revised

January 20194 Revised Section 13

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